Aircooled VW South Africa

that some serious work you've put in thus far, i reckon this buggy is gonna be scary-fast

We use an epoxy at work to make sure bushes nice and tight!
The epoxy we use is called UHU PLUS ENDFEST300.
The stuff can handle high temperatures as well as oil and fuel!
Most if not all of our gearboxes use it somewhere during the assembly process!

Really neat and impressive work done here.

Finally I can add some progress. You won't believe this but, I've been waiting for the Deutz cylinders to be done since July!!
The first engineering shop didn't touch the project until I took the cylinders away mid September, then they were supposed to be done end October at a different shop, but I only got them end November. This now means the car won't run this year, there is simply not enough time left.

To fit these, took 2 and a half days of hand filing and grinding, an ENORMOUS effort!!
The issues were: fins had to ground down between the cylinders, I had to remove some fins to get the cylinders past some places on the casing and I had to ensure there is enough space around the studs so that the cylinders did not wedge between the studs. Cylinders are 101.9mm
Here's couple of pics.

I see I haven't posted a pic of the buggy with the new rear tyres:
Front wheels are basic EMPI 5 spoke in 15" the rears are American racing wheels 17" and I tried to match the design to the EMPI's.



Lekka fat takkies for the back - 265 x 17, soft rubber Yokohama's

hawt hawt hawt...................I dig that stance............

looks good, nice progress.

Baie Mooi man

Glad you came right with the Sleeves

Pierre, yes the sleeves were done after a LOT of hassles by a small little shop here. I happen to meet a guy over a brandy and coke and he was willing to tackle the job.

But here's the full story - you be the judge..

After I took the sleeves from ENSCO Engineering they were brought to this little shop (I don't even know the business's name) solely because I was becoming desperate to get the job done. They did have the large chuck and lathe to do the job, but NO experience with VW cylinders.

After they did the job, I had to take the cylinders for honing to yet another shop (HENTER'S). This is where things got really weird.

Henter's shop phones me and says they can't work on the cylinders because they are "oval" and some are over size and some are under size. So now I'm in a panic....

Drove there and in the mean time I'm phoning the previous engineering shop to tell them what these guys are claiming.
Now, what was true was that the cylinders did differ by 0.003 mm. Now I don't know, but 0.003mm is not an issue for me - clearance needs to be at 0.1mm and I'm not concerned about 0.003mm (don't know if you'll agree). At the end of the day HENTER'S only did the honing after I absolved them of any responsibility for the cylinders.

To me it seems these shops are simply trying to blacken the competition's name. As per usual, the customer is just a nuisance and rivalry is more important than getting a quality job done.

I did the best I could to measure the cylinders and they seem good to me.
Total cost:R7000.00

AirPower wrote:Total cost:R7000.00

Dude that's a lot of $$$.
Crap service ... yes sad indeed, what I am finding more often as well is quality is no longer a concern, shops cry there is no work and when you ask them for something a little diffrent there is allways a problem & excuses and or finger pointing. Found this out again recently the hard way with a set of custom hubs for my boet's Lancia after the buck was passed several times with huge costs to my boet.

Back to the topic, awsome work dude, will be a fire breather of note I'm sure.

I have my cylinders waiting for me in storage once I've fin the current motor...

Keep going. You can do it..

Thanks for the replies.

Today CC'ed the heads, they came in at 72, 72, 73 and 71 cc and after I reworked them some more they are now 73 cc chambers.
Compression ratio works out at 7.8:1 with 1mm deck and 7.6:1 if I increase the deck to 1,5mm but I think the 7.8:1 will be OK considering the cam and a bit of overlap.
I've also set the angle of the rockers and and swivel feet. These LOOK OK to me (first attempt) - the angle looks the same at full lift (12mm) just of course the other direction. Shims under the rocker stands are HUGE, 2mm thick.

Nice work

Air power what happened to this project